Pile yarn attachment for carpet looms



Aug. 28, 1956 H. P. SONTAG ETAL 2,760,520

PILE YARN ATTACHMENT FOR CARPET LOOMS Filed May 2, 1955 9 Sheets-Sheet 1 TO CREELS FIG. 7.

REAR HEDDLE 32 FRONT HEDDLE 28 MIDDLE HEDDLE 29 NOVEL PILE YARN FEED TUBE HOOKS HOLDING PREVIOUS LOOPS 54 SINGLE WARP (JUTE) 22 TO CREELS DOUBLE WARP (COTTON) I YARN JUMBOLD 42 FIG. 2.

MIDDLE HEDDLE 29 FRONT HEDDLE 28 REAR HEDDLE 2 HOOKS HOLDING LOOPS 54 OPEN TOP REED48 JUTE FILLING SHOT SECOND PIOK INVENTORS HERBERT I? 801V TAG HERMAN E SALOMON GERALD E. HERRNSTADT BY M ATTORNEYS Aug. 238, 1956 H. P. SONTAG ET AL 2,760,520

FILE YARN ATTACHMENT FOR CARPET LOOMS Filed May 2, 1955 9 Sheets-Sheet 2 TO CREELS FIG. 3. 34

3/?!) P/GK REED as YARN FEED ROLL 40 MIDDLE HEDDLE 2.9

REAR HEDDLE 32 HOOKS HOLDING FRONT HEDDLE 28 PREVIOUS LOOPS 54 FRONT HEDDLE 2a MIDDLE HEDDLE 29 I NOVEL PILE YARN FEED TUBE 46 F REAR HEDDLE 32 I6. 4. OPEN TOP REED 4e HOOKS IN POSITION T0 PULL 4TH PICK IN NEXT LOOP 54 JUTE FILLING SHOT INVENTORS HERBERT SONTAG HERMAN E SALOMON GERALD E. HERRNSTZIDT ATTORNEYS Aug. 28,1956 H. P. SONTAG ET AL 2,769,520

FILE! YARN ATTACHMENT FOR CARPET LOOMS Filed May 2, 1955 9 Sheets-Sheet 3 FIG. 6.

49 M p r F n W FIG. 7; FIG. 5.

INVENTORS HERBERT I? SONTAG HERMAN E SALOMON GERALD E. HERR/VSTZIDT ATTORNEYS Aug. 28, 1956 H. P. SONTAG ETAL FILE YARN ATTACHMENT FOR CARPET LOOMS 9 Sheets-Sheet 4 Filed May 2, 1955 YARN FFfOM GREELS YARN INDEXING RATGHET YARN JUMBOLD m T m mm mm V MN NNOR IOLR AE RSH r R D E L BM A m HHG ATTORNEYS Aug. 28, 1956 H. P. SONTAG ET AL 2,760,520

FILE YARN ATTACHMENT FOR CARPET LOOMS Filed May 2, 1955 9 Sheets-Sheet 5 YARN RAISING CAM 93 INVENTORS HERBERT]? SONMG HERMAN E SALOMON GERALD E. HERE/VS 72107 BY M 1;- 6244 ATTORNEYS Aug. 28, 1956 H. P. SONTAG ETAL PILEI YARN ATTACHMENT FOR CARPET LOOMS 9 Sheets-Sheet 6 Filed May 2, 1955 INVENTORS HERBERT .SOIVTAG' HERMAN 1-? SALOMON GERALD E. HERR/VSTADT BY M ATTORNEYS Aug. 28, 1956 H. P. SONTAG ETAL 2,760,520

FILE YARN ATTACHMENT FOR CARPET LOOMS Filed May 2, 1955 9 Sheets-Sheet 7 INV HERBERT I? SONTAG HERMAN E SALOMON ENTORS GERALD E. HERR/vsmm ATTORNEYS Aug. '28, 1956 H. P. SONTAG ETAL 2,760,520

FILE YARN ATTACHMENT FOR CARPET LOOMS Filed May 2, 1955 9 Sheets-Sheet 8 INVENTORS HERBERT I? SONTAG HERMAN E SALOMON GERALD E. HERRNSMDT ATTORNEYS Aug. 28, 1956 H. P. SONTAG ETAL 2,760,520

FILE YARN ATTACHMENT FOR CARPET LOOMS Filed May 2, 1955 9 Sheets-Sheet 9 GERALD E. HERRNSMDT BY M A M ATTORNEYS PILE YARN ATTAC i NT FOR CARPET LOOMS Application May 2, 1955, Serial No. 505,381

7 iiiaims. (Cl. 139-48) The present invention relates to an attachment which is adapted to use with various types of looms for the purpose of making heavy pile fabrics such as carpets, rugs or the like.

One of the oldest known modes of rug making is that of hooking the face pile yarn manually, with an especially designed needle, through a previously woven backing such as burlap, duck or the like. In the present mechanical age this is a slow and tedious process. It requires that the backing be woven prior to the hooking of the face pile yarn into such backing materials, which must be stretched over a frame so as to enable the carpet maker to manually insert the pile face yarn back and forth through the backing with a hooking rug needle.

It is, therefore, a primary object of this invention to provide mechanism attachable to a power loom that will perform not only the functions of a manually operated hooking rug needle, but will also weave the backing material simultaneously in coordination with the hooking operation.

Furthermore, it is the object of this invention to provide mechanism which can be attached to a power loom for the weaving of pile into fabrics independently of the apparatus for the weaving of the fabric base, but providing a coordinated continuous operation.

More specifically, it is an object of this invention to provide attachable mechanical units for inserting pile yarn onto a flatly woven fabric base, and thereby adapting a loom which is otherwise not suited for fabrics other than flatly woven ones to manufacture of heavy pile fabric floor covering.

Still another object of this invention is to have one component of the attachable mechanism perform the function of a multitude of manually operated hooking rug needles, although differing substantially from the structure of manually operated needles.

A still further object of this invention is to provide banks of novel pile yarn feed tubes that can be attached to practically any ordinary loom utilizing yarn hooks or pile wires to convert it to a pile fabric loom without interfering with the usual draw-in through the heddle frames, or the motion of the frames as such.

These and other objects of this invention will be more fully understood from the following detailed description of a preferred embodiment, when taken in conjunction with the accompanying drawings, in which:

Fig. l is a side elevational view of the working parts of a loom to which the mechanism of this invention has been attached;

Fig. 2 is a similar side elevational view with the loom in the position of the second pick;

Fig. 3 is also similar to Fig. 1, except that the loom is in the position of the third pick;

Fig. 4 is also like Fig. 1 except that the loom is in the position of the fourth pick;

Fig. 5 is a side elevation of a pile yarn feed tubeattachmerit;

atent Fig. 6 is a top plan view of the feed tube attachment of Fig. 5;

Fig. 7 is a front view of a reed used in conjunction with this invention;

Fig. 8 is an end elevational view of a power loom showing the cam shafts, cams and related mechanisms for operating the heddles, yarn feed tubes, and yarn hooks thereof;

Fig. 9 is a side elevational view of the loom of Fig. 8;

Fig. 10 is a partial top elevational view of Fig. 8 showing further details of the yarn hook cam;

Figs. ll, l2, l3 and 14 are like side elevational views of the working parts of a wire type loom (Wilton, velvet, or the like) in successive, stepwise positions of operations, and to which the mechanism of this invention has been adapted.

With reference to Figs. 1, 2, 3 and 4 of the drawings in which the main loom framework is omitted for clarity and numerous details are shown fragmentarily or semidiagrammatically to emphasize the primary components of the attachment invention here involved, the relative positions of the weave and pile loop forming elements are shown for four successive picks. The required warpwise ends are supplied from the stutter warp beam 20 supplying a single jute warp end, a binder warp beam 22 from which double warp cotton binder is drawn and passes in front of roller 24 and in back of roller 26, which form a conventional jumbold, before being led through a front heddle 28 and a middle heddle 29 respectively. The stuffer warp yarn from beam 20 is fed in front of roller 30 and in back of roller 31, which are arranged in jumbold relation, and then through the rear heddle frame 32. It will be understood that these primary components of the drawings are known and are presented to facilitate explanation and understanding of the purposes of this invention. Since there are very few looms which have a capacity of less than four heddle frames, it is for this reason that three frames are used in the illustrative embodiment of the invention. Any deviation from this number would not differ essentially from the principle of the invention.

Attention will now be given to the face yarn feed which is a practical necessity for the present loom attachment. This attachment lends itself to the manufacture of pile fabrics of either equal or alternately high and low pile height. It is preferred, however, to use creels for the face yarn instead of beams, although beams are entirely satisfactory in those instances where an equal or even pile height is required throughout the fabric. As the face or pile yarn 34 is fed from creels, indicated only by legend, and passes through an open reed 36, under an idler roll 38 and over a feed roller 40. From the feed roller 40 the creel supplied yarn is led over a yarn jumbold 42 of a small assembly, which is a part only of the loom attachment of this invention, which is designated generally as 4-4. From jumbold 42 the yarn is led through a pile yarn feed tube 46 extending vertically and having a particularly advantageous configuration which will be subsequently described in detail.

Since the face yarn does not go through any of the heddle frames, the loom attachment 44 requires as one of its working parts an open top reed 48 shown in detail in Fig. 7, in order that the face yarn will be kept out of the way of the various warp and stuifer ends. A plurality of spaced hairpin reed dents 49 of metal have their lower ends secured in the fixed, non-oscillatory lay 50 as indicated. The pile warp yarns are received between the reed dents 49, and the other Warp yarns arethreaded through the hairpin formations; While open top reeds are generally known of themselves, the utilization of an open reed 48 as illustrated in Fig. 7 is necessary:

Patented Aug. 28, 1956 in Combination with the novel pile yarn feed tube 46 in order to achieve the purposes of this invention.

It is only in the first pick position shown in Fig. 1 that the pile yarn feed tube 46 is in a position of interference in the sheds. Thus the face yarn is brought to the rear of a lay 50 carrying the open top reed 48.

While a closed top type of reed may be employed, an open top reed is definitely preferred. With the closed top common type reed the shed opening is limited to a degree, but the weaver is confined to use of the warp thread pile yarn in the same warpwise space at all times. This limitation is avoided by use of the open top reed 43 of Fig. 7.

A further attachment part is required to perform the function of making the pile, holding the same in place, and releasing the same, and then moving into position for the next loop of pile yarn. For this purpose there is provided a longitudinally pivoted hooking bar 52 with spaced hooks 54 attached thereto in the necessary pitch for holding or releasing the pile yarn at the times required.

To further clarify the operation of the loom attachment of this invention there is shown in Fig. 1 a combination of the warps and the pile yarn and the relation of the attachment thereto in the first pick of a Weave that may be made by use of the invention, but is not itself a part thereof. As will be observed, the yarn frame or loom attachment 44 is at its lowermost position while the rear heddle 32 and the front heddle 28 are up, with the middle heddle 29 remaining down.

In the second pick, which is shown in Fig. 2, the positions of the heddle frames are reversed, with the rear heddle 32 and the front heddle 28 being down, and the middle heddle 29 being up, and the yarn frame attachment 44 being half-way up. At the same time the books 54 are holding the loops previously made so that upward movement of said attachment cannot withdraw the yarn previously formed into piles.

1n the third pick (Fig. 3) the pile yarn feed tube 46 remains in the same position as in the second pick, this position being half-way up its path of movement. The hooks 54 continue to hold the previous loops, and the heddle frames are reversing in such a manner that the rear heddle 32 is up, the middle heddle 29 is up, and the front heddle 28 is down.

In the fourth pick (Fig. 4), the rear heddle 32 and the middle heddle 29 are reversing their positions again and are both down, and the front heddle 23 also reversing itself is up in order for insertion of a jute filling shot. In this fourth pick, which may be regarded as the last pick of a cycle, the pile yarn feed tube 46 is in its most elevated position, which brings the yarn fed therefrom appreciably above the binder thread fed through the front heddle 28. This position is also above the open top reed r 48. While the pile yarn is now held in its highest position by the feed tube 46, the hook bar 52 is moved in a direction to release the pile yarn it previously held, and slightly beyond the same in a laywise direction to the oncoming yarn, so that such yarn snaps into the hooks 54. By repeating the cycle back to the first pick (Fig. 1) in which the hooking bar 52 that holds the hooks 54 returns to its lower position while the pile yarn feed tube 46 moves to its lowermost position, the new row of pile is formed.

Therefore, the cycle of operation involves a three-level movement, namely, the fully elevated position of Fig. 4 necessary for the hooks 54 to grasp the pile yarn, the fully down position of Fig. 1 required to dispose a filling shot above the pile yarn fed and integrate the pile yarn with the base weave, and the position of intermediate elevation of Figs. 2 and 3, required to satisfy the base weave requirements without interference from the pile yarn.

The essential operation of the mechanism of this invention as explained with references to Figs. 1, 2, 3 and 4 combines a three-level up and down movement of the loom attachment assembly 44 in cooperative relation with a common flat weave loom operation.

The details of the pile yarn feed tube 46 are most clearly shown in Figs. 5 and 6. Each tube 46 has an upwardly extending bracket 60 secured to the front side of the upper end portion thereof and being of strip for mation of lesser thickness than the tube itself. The several tubes 46 are individually joined with a movable support 62 for up and down movement together as illustrated in Figs. 1 to 4.

T he yarn feed tubes 46, all of which are alike, are of flattened elliptical cross-section as shown in Fig. 6 and each includes an upstanding mounting bracket 60 secured to its upper end portion at one side and being of fiat strip formation of lesser thickness than the narrower side of the tube to which it is connected. These mounting brackets or strips 6% are secured in parallel relation and alignment to a movable support 62 for up and down movement together as indicated by the sequential positions of Figs. 1 to 4. The upper end of the tube 46 is formed with a lip or bevelled mouth 64, and the lower end portion 66 thereof is curved outwardly so as to be generally coplanar with the bracket 60 and the main body of the tube itself and to present a gently curved yarn guiding passage terminating in an opening on the bracket side of the tube that is substantially parallel to the vertical straight side of the tube. A generally triangular, bladed end piece 68 is secured to and depends from the lower surface of the curved end portion 66 adjacent the lower and opening of the tube 45. The end piece has a straight edge beneath the discharge end of the tube 46, and is reduced to a relatively dull horizontal edge 70 at its lowermost extremity. The purpose of the elliptical crosssection and the bladed end piece 68 is to facilitate insertion of the lower end portion of the feed tube 46 between the Warp ends passing through the heddles 28, 29 and 32. The pile yarn, which may be quite bulky, smoothly enters the feed tube 46 through the lipped mouth 64 and is conformed generally to the elliptical cross-section before passing out through the opening at the lower end portion thereof. Thus each tube 46 of itself performs the function of a manually operated rug hooking needle as used in the hand hooking rug process.

Figs. 8, 9 and 10 show in detail the loom mechanisms for operating the pile yarn feed roller 40, the heddles 28, 29 and 32, the yarn books 54, and the yarn feed tubes 46 in accordance with the purposes of this invention. Accordingly, only the loom devices pertinent to these operations will be referred to. In Fig. 8 there is shown a yarn ratchet cam operating a connected linkage and mechanism designated generally as 77 for controlling the pile yarn feed to the yarn feed tubes 46. A yarn hook operating cam 79 actuating a linkage designated generally as 81 produces the required motion of the yarn hooks 54 in the requisite sequence. A commonly driven set of heddle cams 83, 85, and 87 are connected with heddles 28, 29, and 32, respectively, to perform the four pick cycle that has been described in detail. A yarn hook shifting cam operating a linkage 91 is shown in Fig. 10 as well as Fig. 8. A yarn tube raising cam 93 coupled with linkage and mechanism 95 for performing this function is shown in Figs. 8 and 9.

The adaptability of the principles of this invention to a loom in which pile wires are used instead of books, reference will now be made to the modified combination illustrated by Figs. 11, 12, 13 and 14. In this instance the novel pile yarn feed tubes of this invention operate without the cooperation of hook bar or hooks, which are replaced by conventional pile wires having a pile yarn fed thereover and thereunder.

While the loom of Figs. 11, 12, 13 and 14 with its modified combination embodying a set of pile wires in place of a hook bar also requires a cycle of four picks, the pile yarn feed tube 46 has a somewhat difierent cooperating action. As seen in Fig. 11, in the first pick of the cycle the pile yarn feed tube 46 is all the way above the open top reed 48, the stutter warp from beam 20, and the binder warp yarn from beam 22, and lies above one of the pile wires 100 about to create the pile in the following pick. In the first pick the rear and middle heddle frames 32 and 29 are up and the front heddle frame 28 is down. In Fig. 12 showing the second pick, the rear and middle heddle frames 32 and 29 are down and the front heddle frame 28 is up. In this second pick the pile yarn feed tube 46 has fed the pile yarn in between the open spaces of the open end reed 48 and a jute thread is inserted above the pile yarn, while a pile wire 100, which in the first pick is ready to be inserted, has been introduced under the pile yarn. In the third pick shown in Fig. 13 a pile wire 100, which in the first pick was ready to be inserted, will create a pile formation PF in the same manner as the outermost pile wire 100 did originally. So too in Fig. 13 the pile yarn feed tube 46 moves up again above the open top reed 48 and the lay 50, and another pile wire 100 is positioned for insertion in the following pick. In this third pick the rear heddle 32 and the front heddle 28 are up while the middle heddle 29 is down. Fig. 14 shows the last one of the four picks required to complete a cycle, and has the pile yarn feed tube 46 being in the same down position as it was in Fig. 12, the only variance being that the middle heddle 29 is up and the front heddle 28 as well as the rear heddle 32 are down. This set of pile wires 100 is operated in the usual sequential manner for the purpose.

Although a preferred embodiment and certain modifications of this invention have been described in detail, it will be understood that various changes can be made in details of construction and arrangement of parts, without departing from the inventive principles and the scope of the appended claims.

Having thus described our invention, what we claim as novel and desire to secure by Letters Patent of the United States is:

1. In a loom for weaving pile fabrics, the combination comprising a lay having an open top reed, a unit of pile yarn feed tubes in back of the reed, a hook bar unit carrying a plurality of hooks positioned in front of the reed, and means raising and lowering the feed tube unit and swinging the hook bar until back and forth in cyclic relation to form and insert pile yarn loops in backing material woven by the loom.

2. The combination of claim 1 in which the pile yarn feed tubes are of flattened oval cross-section with their flat sides parallel and have outwardly curved lower ends directed toward the lay.

3. The combination of claim 1 in which the reed has spaced hairpin reed dents having their ends secured in the lay.

4. In a loom for weaving pile fabrics, the combination comprising a lay having an open top reed, a unit of pil yarn feed tubes in back of the reed, a set of pile wires positioned in front of the reed, and means raising and lowering the feed tube unit and inserting and withdrawing the pile wires in coordinate relation to feed the pile yarn ends from the feed tube unit over and under the pile wires and insert the pile yarn in the backing material woven by the loom.

5. In a loom for weaving pile fabrics, the combination comprising a lay having an open top reed, a unit of pile yarn feed tubes in back of the reed, pile raising means positioned in front of the reed, and means raising and lowering the feed tube unit and inserting and withdrawing the pile raising means in coordinate relation to form and insert the pile yarn as loops in the backing material woven by the loom.

6. A carpet loom attachment for inserting pile yarn loops in a backing as woven, said attachment comprising a vertically movable support, and a plurality of pile yarn feed tubes depending in parallel from the movable support, each of said feed tubes being of flattened oval crosssection and having a lipped mouth at its upper end, an outwardly curved lower end portion, and a bladed end piece depending from the curved end portion for aiding in inserting the feed tube between warp ends.

7. A pile yarn feed tube for carpet looms, said tube having a flattened oval cross-section, a lipped mouth at its upper end, an outwardly curved lower end portion, and a bladed end piece depending from the lower end portion and having a straight edge positioned beneath the extremity of the lower end portion of the tube and terminating in a reduced edge.

References Cited in the file of this patent UNITED STATES PATENTS 2,610,652 Parker Sept. 16, 1952 2,638,934 Parker May 19, 1953 2,710,028 White June 7, 1955 2,715,918 Eisler et al. Aug. 23, 1955 

